[introduction] in the value flow chart, lean production perspective under the guidance of various processes on the independent improvement project has been given a new meaning to make employees clear the implementation of the project, there are 7 main methods for continuous improvement of production process.
Eliminate the phenomenon of quality inspection and rework
If the quality of the products from the beginning of the product design, until the whole product made from the production line, the quality of each link can be a hundred percent guarantee, then the quality inspection and rework phenomenon naturally became the excesses.
Must “ error protection ” ideas throughout the entire production process, that is to say, from the beginning of product design, quality problem has been taken into account, ensure that each product can only be strictly in accordance with the correct way of processing and installation, thus avoiding possible errors in the manufacturing process. The elimination of rework is mainly to reduce the waste generated, closely watching all kinds of waste products (such as equipment, staff, materials and methods of operation, etc.), to identify the root causes, and then completely resolved.
Two, eliminate unnecessary movement of parts
The production layout is not reasonable is the root cause from the moving parts, in according to the process of professional organization in the workshop, the parts often need to move in several workshops, the production line is long, long production cycle, and take up a lot of inventory, resulting in high production cost.
By changing the unreasonable layout, the production requirements of the equipment according to the processing sequence arrangement, and be as compact as possible, so as to shorten the transport route, eliminate unnecessary moving parts and unreasonable material movement, saving production time.
Three, the elimination of inventory
In the lean production enterprise, inventory is considered the biggest waste, because the inventory will cover many problems in the production of workers will breed inertia, even worse is to take up a lot of money, so as to solve the inventory of production and sales of the anxious is like drinking poison to stop thirsty.
A strong measure to reduce inventory is to change “ batch production, queue supply ” “ single production process ”. In the production process, there is basically only one piece of production flow between the various processes, the whole production process with the single production process and always keep the flow.
Ideally, no inventory in the process between adjacent. Of course it is not possible, in some cases, taking into account the adjacent two processes of transition time, must also keep a certain amount of inventory, the ideas and methods of elimination of inventory lean production and JIT production JIT similar concepts and methods.
Four, reasonable arrangements for the production plan
From the point of view of production management, the balance of the production plan to play the most productive system efficiency, to make reasonable arrangements for the work plan and staff. To avoid a process of working load for a while too high, while too low.
In the continuous production process continuously, must also be every procedure to balance production unit, requires the completion of each operation takes roughly the same time, so that each operation or set of operations and production line of single production time match. Production time is to meet the needs of users of the production time, can also be considered to meet the market's beat or rhythm. In strict accordance with the Tacttime organization of production, the finished product inventory will be reduced to a minimum.
Five, reduce production preparation time
The general practice is to reduce production preparation time, carefully and carefully before the start of all preparation activities, to eliminate all kinds of hidden dangers in the production process may occur.
Identify which factors are intrinsic (need to be shut down in order to handle), which are external factors (in the production process can be processed);
As far as possible, the internal factor is the external factor;
The use of industrial engineering methods to improve technology, streamline all the internal and external factors that affect the preparation of production, so that efficiency is improved.
Six, eliminate downtime
Eliminating downtime for maintenance of continuous production is significant, because the continuous production process, the two processes between less inventory, if the machine once the failure, the entire production line will be paralyzed. The most effective measures to eliminate the down time is the comprehensive production and maintenance, including routine maintenance, predictive maintenance, preventive maintenance and immediate repair four basic maintenance methods are described in detail as follows:
The routine maintenance: maintenance activities made by the operators and maintenance workers every day, need regular maintenance of machine.
Predictive maintenance: the use of measurement and analysis techniques to predict the potential failure to ensure that the production equipment is not due to machine failure caused by the time of loss. It is a rainy day, nip in the bud.
Preventive maintenance: prepare files for each machine, record all maintenance plan and maintenance records. For each part of the machine to do a thorough, strict maintenance, timely replacement parts, to ensure that the machine does not happen accident. Overall production and maintenance of the target is no downtime. To achieve this goal, it is necessary to focus on eliminating the root causes of failure, rather than just to deal with the daily maintenance tasks.
The immediate maintenance: when a fault occurs, the maintenance staff to call, call, timely treatment.
Seven, improve labor utilization
To improve the utilization rate of labor, including two aspects, one is to improve the direct labor utilization, the two is to improve the utilization of indirect labor.
Improve the utilization rate of direct labor is the key to cross training for operators, so that one can be responsible for multi machine operation, make the production line operator can adapt to any type of work in production line. Cross training gives great flexibility to the workers, so that it is easy to coordinate and deal with the abnormal problems in the production process.
Another way to improve the utilization rate of direct labor is to install the automatic detection device on the production equipment. Throughout the production process in the automatic detection device under close monitoring, once detected in the production process of any abnormal situation occurs, it will issue an alarm or automatic shutdown. These automatic detection devices to a certain extent replaced the quality of the work of the detection of workers, to eliminate the cause of quality problems, rework phenomenon alsoGreatly reduced, the utilization rate of natural increase.
Indirect labor utilization is mainly to eliminate indirect labor. From the point of view of value chain, the consumption of inventory, inspection, rework and other aspects of human and material resources, and can not increase the value of the product, so that the labor is usually considered indirect labor, to eliminate the indirect activities in the value chain of value-added products, so the indirect costs caused by these activities will be significantly indirect lower labor utilization was improved, is conducive to the improvement of direct labor utilization measures can also improve the rate of indirect labor.